Non-round metallic pressurized container and method of manufacturing same

ABSTRACT

A metallic container includes a metallic elongated body that provides an interior cavity. The body has a non-circular perimeter wall, a bottom and a top. The perimeter wall is joined to the bottom at one end and to the top at an end opposite the bottom. The top includes an opening having a lip. The perimeter wall extends in a longitudinal direction to provide a height. The perimeter wall includes a cross-section normal to longitudinal direction that provides a major diameter and a minor diameter. A ratio of the major diameter to the minor diameter is 1.3 to 2.0. A valve assembly is operatively secured to the lip over the opening to enclose the cavity.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 61/978,284, which was filed on Apr. 11, 2014 and is incorporated herein by reference.

BACKGROUND

This disclosure relates to a non-round metallic pressurized container and a method for manufacturing the same.

Metallic containers are typically used for aerosol applications. Typically, a cylindrical container is formed from steel or aluminum. The bottom is often a spheroidal dome, and the top may also be domed or have a conical shape. The top and/or bottom may be seamed to an elongated cylindrical perimeter wall. A valve assembly, which is used to dispense the fluid in an aerosol, is crimped to a lip that circumscribes an opening on the top.

Conventional metallic aerosol containers may be unsuitable for some applications. For example, it may be desirable to use an aerosol container by carrying it on one's body, for example, on a belt. For such applications, a much smaller, lower profile, and less obtrusive (or protruding) container may be desirable. However, a lower profile cylindrical container configuration may not have sufficient capacity due to its reduced size. Suitable non-cylindrical shaped containers have not yet been developed for aerosol container applications, and in particular, smaller applications.

SUMMARY

In one exemplary embodiment, a metallic container includes a metallic elongated body that provides an interior cavity. The body has a non-circular perimeter wall, a bottom and a top. The perimeter wall is joined to the bottom at one end and to the top at an end opposite the bottom. The top includes an opening having a lip. The perimeter wall extends in a longitudinal direction to provide a height. The perimeter wall includes a cross-section normal to longitudinal direction that provides a major diameter and a minor diameter. A ratio of the major diameter to the minor diameter is 1.3 to 2.0. A valve assembly is operatively secured to the lip over the opening to enclose the cavity.

In a further embodiment of the above, the top is at an angle from the perimeter wall to the lip of less than 20°.

In a further embodiment of any of the above, the cross-section is oval.

In a further embodiment of any of the above, the cross-section is kidney-shaped.

In a further embodiment of any of the above, the height from the bottom to the lip is less than 3.25 inches (8.26 cm).

In a further embodiment of any of the above, the top is free of wrinkles.

In a further embodiment of any of the above, the top is at an angle from the perimeter wall to the lip of less than 10°.

In a further embodiment of any of the above, the bottom is substantially flat.

In a further embodiment of any of the above, the bottom is substantially concave or substantially convex.

In a further embodiment of any of the above, a perimeter wall thickness is in a range of 0.008 to 0.025 inch.

In a further embodiment of any of the above, a bottom wall thickness to the perimeter wall thickness has a ratio of about 1:2.

In a further embodiment of any of the above, the body is an aluminum alloy or a steel alloy.

In a further embodiment of any of the above, the cavity includes a liquid pressurized to at least 25 psi. The body is exposed to the liquid.

In a further embodiment of any of the above, the perimeter wall, the top and the bottom are provided by a one-piece, unitary structure without any securing seams.

In a further embodiment of any of the above, the body includes a first portion and a second container portion secured to one another at a joint to provide the cavity.

In a further embodiment of any of the above, the first container portion includes the top, and the second container portion includes the bottom. The first and second container portions are nested relative to one another to provide the perimeter wall.

In a further embodiment of any of the above, the first and second container portions overlap one another in a longitudinal direction by at least 5%.

In a further embodiment of any of the above, the first and second container portions are glued to one another.

In a further embodiment of any of the above, the joint is welded or seamed.

In a further embodiment of any of the above, the lip includes a rolled cross-section.

In another exemplary embodiment, a method of forming a container includes the steps of impact extruding a non-circular metallic slug to form an elongated body that includes a non-circular perimeter wall joined to an end wall. The end wall provides one of a top with an opening or a substantially flat bottom free from openings. The top is necked to provide an angle from the perimeter wall to a lip in the top of less than 20°. The lip is curled about the opening. A valve assembly is operatively secured to the lip over the opening.

In a further embodiment of any of the above, the slug is oval-shaped or kidney-shaped. The perimeter wall respectively includes an oval cross-section or a kidney-shaped cross-section.

In a further embodiment of any of the above, the oval-shaped or kidney-shaped slug has a hole in the slug.

In a further embodiment of any of the above, the impact extruding step forms the top to provide a first container portion and comprising the step of securing a second container portion to the first container portion. The second container portion includes the bottom.

In a further embodiment of any of the above, the first and second container portions are nested relative to one another to provide the perimeter wall.

In a further embodiment of any of the above, the first and second container portions are glued to one another.

In a further embodiment of any of the above, the first and second container portions are welded to one another.

In a further embodiment of any of the above, the impact extruding step forms the bottom. The necking step is provided on the perimeter wall using multiple dies to provide the top free of wrinkles.

In a further embodiment of any of the above, the necking step provides an angle from the perimeter wall to a lip in the top of less than 10°.

In a further embodiment of any of the above, the perimeter wall, the top and the bottom are provided by a one-piece, unitary structure without any securing seams.

In a further embodiment of any of the above, the method includes filling the container with a liquid and a pressurized propellant.

In a further embodiment of any of the above, the impact extruding step forms the top to provide a first container portion and comprising the step of securing a second portion to the first container portion. The second portion is a bottom cover.

In a further embodiment of any of the above, the first and second container portions are nested relative to one another.

In a further embodiment of any of the above, the first and second container portions are glued to one another.

In a further embodiment of any of the above, the first and second container portions are welded to one another.

In a further embodiment of any of the above, the first and second container portions are seamed to one another.

In a further embodiment of any of the above, the bottom cover is stamped.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure can be further understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIGS. 1A-1C respectively illustrate perspective, side elevational and top elevational views of one example container.

FIGS. 2A-2E respectively illustrate perspective, side elevational, front elevational, top elevational and bottom elevational views of another example container.

FIG. 3A is a partial cross-sectional view through one example container.

FIG. 3B is a partial cross-sectional view through another example container.

FIG. 4A is an enlarged cross-sectional view through a portion of a valve assembly secured to a lip.

FIG. 4B is another example of an enlarged cross-sectional view through a portion of a valve assembly secured to the lip.

FIG. 5A is one example securing configuration.

FIG. 5B is another example securing configuration.

FIG. 5C illustrates an example seaming configuration for a non-round can.

FIG. 5D illustrates a bottom secured to a top portion.

FIG. 6 is a flow chart depicting an example method of manufacturing the disclosed container.

FIG. 7 is a schematic view of an example impact extrusion machine.

FIG. 8 is a schematic view of an example die assembly used is forming the top of the disclosed container.

FIGS. 9A and 9B schematically illustrate the non-circular container being formed throughout the manufacturing process.

The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

DETAILED DESCRIPTION

The disclosed containers are suitable for a variety of small-scale applications in which it is desirable to maximize holding capacity while maintaining a low container profile. One example application is set forth in U.S. application Ser. No. 13/464,527, entitled “DISPENSER ASSEMBLY FOR DISPENSING FLUID AND METHOD FOR USE THEREOF AND DATA COLLECTION AND MONITORING SYSTEM FOR MONITORING AND REPORTING DISPENSING EVENTS,” now issued as U.S. Pat. No. 8,844,766, which is incorporated by reference in its entirety.

One example non-round metallic container 10 is illustrated in FIGS. 1A-1C. The container 10 includes an elongated body provided by a non-cylindrical or non-circular perimeter wall 12. The shape of the perimeter wall 12 is such that a low profile is provided, which is suitable for mounting against a user's body, for example. The elongated body includes a bottom 14 provided at one end of the perimeter wall 12 and a top 16 at an end opposite the bottom 14. The perimeter wall 12 is kidney-shaped, which enables the container 10 to closely follow the contour of a user's hip if the container 10 is carried around the user's waist on a belt, for example.

A valve assembly 18 is operatively secured to the top 16 to provide an enclosed cavity filled with fluid. In one embodiment, the container 10 is filled with a fluid that is pressurized. Depressing the valve assembly 18 dispenses the fluid in an aerosolized form. In one example, the fluid is a sanitizer, such as ethyl alcohol and/or benzalkonium chloride.

The container 10 is constructed from any suitable material. In one example, the container is formed of plastically deformed steel or aluminum, for example, a 1070 aluminum alloy. It should be understood that other suitable materials may also be used. A typical container pressure for aerosol applications is 120-180 psig typically tested at 130° F. Due to the non-cylindrical shape of the container 10, it is difficult to design a container that passes DOT burst test regulations.

Another example container 110 is illustrated in FIGS. 2A-2E. The elongated body includes a substantially flat bottom 114. Conventional aerosol designs used a spheroidal domed bottom. However, such bottoms can flatten out under high internal pressures, especially in non-round applications, and permit deflection of the elongated body 112 in non-cylindrical applications, which may lead to container rupture. The substantially flat bottom 114 prevents the perimeter wall 112 from expanding near the bottom. Additionally, a substantially flat bottom 114 allows the container 110 to be filled with a greater quantity of fluid. In certain applications, however, a domed bottom may be desired, as shown with the dotted lines in FIG. 1B, and is considered as part of this application.

The top 116 includes a lip 20 that circumscribes an opening over which the valve assembly 118 is secured. The lip 20 may be curled to provide better sealing and ease of assembly of the valve assembly 118 to the body.

The perimeter wall 112 includes a major diameter 22 and minor diameter 24, for example, forming an oval shape. In one example, the ratio of the major diameter 22 to the minor diameter 24 is in a range of 1.3 to 2.0, and in another example, around 1.5. The container 110 has a height 26 from the bottom wall 114 to a top of the lip 20 that is less than 3.25 inches, and in one example around 2.85 inches. This relatively short height enables a user with relatively small hands to easily squeeze the container 110 between the thumb and fingers and dispense the aerosol delivered product directly into the hand from, for example, a belt-mounted location. In one example, the ratio of height 26 to major diameter 22 is between 1.0 to 1.5. The container shape provides a low profile shape suitable for wearing, maximizing capacity and withstanding high internal pressures. However, it should be understood that the size of the disclosed container may be scaled up or down in size depending upon the application.

The top 116 includes a very low profile. The top 116 is arranged at first and second angles 28, 30 from the perimeter wall 112 to the lip 20 of less than 20°. In another example, the first and second angles are less than 10°. The top 116 is formed free of wrinkles.

It is desirable to manufacture the container 110 from a single unitary structure without any seams or securing means, such as seams, welds or adhesives. As shown in FIG. 3A, the perimeter wall 112, bottom 114 and top 116 are provided by a one-piece, unitary structure defining the cavity 32. In the example, for a 1070 aluminum alloy, the perimeter wall thickness 34 is in a range of 0.008-0.025 inch, and the bottom thickness 36 is in a range of 0.008 to 0.050 inch. The thicknesses may be larger or smaller than the specified ranges depending upon the material, for example.

Another example container 210 is illustrated in FIG. 3B. In this example, first and second container portions 38, 40 are formed separately and nested relative to one another to provide a double-walled perimeter wall 212 defining the cavity 132. The first container portion 38 provides the top 216 and lip 220, and the second container portion 40 provides the bottom 214. The perimeter walls of each container portion are secured to one another by an adhesive 42, for example. One example adhesive is manufactured by Henkel as LOCKTITE 331-en with LOCKTITE 7387 activator. The first and second container portions 38, 40 are in overlapping relationship with respect to one another greater than 50% of the container height, and in one example, greater than 80% of the container height. The double-walled perimeter thickness 134 is in the range of 0.016-0.050 inch. Other configurations may be used to form the container such as these described in connection with FIGS. 5A-5D below.

Example valve assemblies 118, 218 are respectively illustrated in FIGS. 4A-4B. Any suitable valve assembly may be used, for example, a standard one inch valve manufactured by APTAR with differing number of stem orifices and sizes. In the example shown in FIG. 4A, the valve assembly 118 is secured over the lip 20 by expanding an inner perimeter 50 in the cap 48 to provide a crimp. A gasket 46 is provided between the lip 20 and the cap 48. In another example shown in FIG. 4B, this skirted valve assembly 218 provides the crimp at an outer perimeter 150 of the cap 148.

If desired, the top and/or bottom may be secured to the perimeter wall at a machined joint 52 in any number of ways including, but not limited to by a glue or weld bead 54, as shown at FIG. 5A. In another example shown in FIG. 5B, first and second terminal ends 56, 58 may be secured to one another by a glue or weld bead 54. FIG. 5C illustrates a seamed joint 55 that connects first and second ends 51, 53. In the example shown in FIG. 5D, a stamped bottom 314 includes a perimeter recess 313 that receives a terminal end of the perimeter wall 312. A laser weld bead 154 secures the bottom 314 to the perimeter wall 312.

A method 60 of manufacturing the container is schematically illustrated in FIG. 6. The method 60 includes the step of impact extruding a non-circular slug, indicated at block 62. The deformed slug forms an elongated body with a non-circular or non-cylindrical perimeter wall and either the top or bottom, as indicated at 64. At one or more stages during the manufacturing method, the top may be trimmed around the opening. The top is necked to provide a shallow angle from the perimeter wall to the lip, as indicated at 66, which provides a low profile container top. In the example of a one-piece container, shown in FIG. 3A, the perimeter wall having the integral bottom is necked to provide the top and lip. In the example of a multi-piece container, shown in FIG. 3B, first and second container portions are formed at step 64 or in one of FIGS. 5A-5C where a separate bottom or top is formed separately and not shown in the schematic diagram.

The lip is curled, as indicated at block 68. The valve assembly is secured over the opening after filling, as indicated at step 70 and schematically shown in FIGS. 4A and 4B.

An example impact extruding machine 72 is schematically shown in FIG. 7. A non-circular slug 78 is placed in a die 74. A ram 76 deforms the slug 78 to create a container blank 80. As the ram 76 retracts from the die 74, the container blank 80 is carried with ram 76. A scraper 82 prevents the container blank 80 from fully retracting along with the ram 76, removing the container blank 80 from the ram 76.

After trimming the container blank 80 is deformed using a die assembly 84, which is schematically illustrated in FIG. 8. The die assembly 84 includes multiple progressive dies 86A-86F. The die assembly 84 carries a suitable number of dies, which forms an end of the container to provide the top with the lip in a manner that produces the top free from wrinkles.

A schematic illustration of the various steps of manufacture of the disclosed container is shown in FIGS. 9A-9B. The non-circular slug 78 is deformed to provide the container blank 80. The open end of the container blank 80 is deformed to provide the very shallow top and lip circumscribed about the opening, as illustrated by intermediate container configurations 88A-88D. The lip 20 is rolled, as indicated by container configuration 90. Finally, the valve assembly 118 is secured relative to the lip 20 to provide the container 110, which is subsequently filled with fluid and propellant such as propane to pressurize the container.

In another example forming method, the top portion of the container is impact extruded. The opening in the top is then trimmed and curled in preparation for receiving the valve. The bottom is formed and secured to the open bottom of the top portion, as shown in FIG. 5D.

A non-round can has many advantages as compared to a round can. It is uniquely shaped compared to conventional containers, increases shelf presence, differentiates a product in the marketplace compared to others using a conventional round can, and make packaging more economical whereby more efficiently utilizing shipping space and shelf keeping unit space at the point of purchase.

It should be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit herefrom. Although particular step sequences are shown, described, and claimed, it should be understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present invention.

Although the different examples have specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.

Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For that reason, the following claims should be studied to determine their true scope and content. 

1. A metallic container comprising: a metallic elongated body providing an interior cavity, the body has a non-circular perimeter wall, a bottom and a top, the perimeter wall joined to the bottom at one end and to the top at an end opposite the bottom, the top includes an opening having a lip, the perimeter wall extends in a longitudinal direction to provide a height, and the perimeter wall includes a cross-section normal to longitudinal direction that provides a major diameter and a minor diameter, a ratio of the major diameter to the minor diameter is 1.3 to 2.0; and a valve assembly is operatively secured to the lip over the opening to enclose the cavity.
 2. The metallic container according to claim 1, wherein the top is free of wrinkles and at an angle from the perimeter wall to the lip of less than 20°.
 3. The metallic container according to claim 1, wherein the cross-section is one of oval or kidney-shaped.
 4. (canceled)
 5. The metallic container according to claim 1, wherein the height from the bottom to the lip is less than 3.25 inches (8.26 cm).
 6. (canceled)
 7. The metallic container according to claim 2, wherein the top is at an angle from the perimeter wall to the lip of less than 10°.
 8. The metallic container according to claim 1, wherein the bottom is one of substantially flat, substantially concave or substantially convex.
 9. (canceled)
 10. The metallic container according to claim 8, wherein a perimeter wall thickness is in a range of 0.008 to 0.025 inch.
 11. The metallic container according to claim 10, wherein a bottom wall thickness to the perimeter wall thickness has a ratio of about 1:2.
 12. (canceled)
 13. The metallic container according to claim 1, wherein the cavity includes a liquid pressurized to at least 25 psi, the body exposed to the liquid.
 14. The metallic container according to claim 1, wherein the perimeter wall, the top and the bottom are provided by a one-piece, unitary structure without any securing seams.
 15. The metallic container according to claim 1, wherein the body includes a first portion and a second container portion secured to one another at a joint to provide the cavity.
 16. The metallic container according to claim 15, wherein the first container portion includes the top, and the second container portion includes the bottom, the first and second container portions nested relative to one another to provide the perimeter wall.
 17. The metallic container according to claim 16, wherein the first and second container portions overlap one another in a longitudinal direction by at least 5%.
 18. The metallic container according to claim 16, wherein the first and second container portions are glued to one another.
 19. The metallic container according to claim 15, wherein the joint is welded or seamed.
 20. The metallic container according to claim 1, wherein the lip includes a rolled cross-section.
 21. A method of forming a container comprising the steps of: impact extruding a non-circular metallic slug to form an elongated body that includes a non-circular perimeter wall joined to an end wall, wherein the end wall provides one of a top with an opening or a substantially flat bottom free from openings; necking the top to provide an angle from the perimeter wall to a lip in the top of less than 20°; curling the lip about the opening; and operatively securing a valve assembly to the lip over the opening.
 22. The method according to claim 21, wherein the slug is oval-shaped or kidney-shaped, and the perimeter wall respectively includes an oval cross-section or a kidney-shaped cross-section. 23.-30. (canceled)
 31. The method according to claim 21, comprising filling the container with a liquid and a pressurized propellant. 32.-37. (canceled) 